Sizer for forming shaped polymeric articles and method of sizing polymeric articles

ABSTRACT

A sizer assembly for providing a shaped polymeric article in an extrusion process comprises a sizer body having a product profile channel corresponding to the shaped polymeric article formed therethrough. The sizer body comprises a plurality of cooling liquid inlet slots forming an opening substantially around the product profile channel and a plurality of vacuum slots forming an opening substantially around the product profile channel for removing cooling liquid expelled from said cooling liquid inlet slots.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application of U.S. patent applicationSer. No. 10/428,227 filed May 2, 2003, entitled “Improved Sizer forForming Shaped Polymeric Articles and Method of Sizing PolymericArticles” now U.S. Pat. No. ______, the entirety of which is herebyincorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates to extrusion techniques, and moreparticularly to sizers used in shaping extruded polymeric articles.

BACKGROUND OF THE INVENTION

FIG. 1A illustrates a side elevational view of a prior art sizer 40 usedin an extrusion system described in U.S. Pat. No. 6,319,456 to Gilbertet al., entitled “Method for Continuous Vacuum Forming Shaped PolymericArticles,” issued Nov. 20, 2001, the entirety of which is herebyincorporated by reference. An extruded sheet 10 is subjected to a sizer40 for mechanical deforming and shaping an extruded sheet. One or morepre-sizers (not shown) may precede the sizer 40. A cross-section of thefinal sizer is shown in FIG. 1B. This device includes a series ofadjustable blocks and plates. The final sizer 40 includes a pair oflateral forming block mechanisms 48 and 52 which can be lever operatedfor a variety of products and sizes. The final sizer 40 also includestop and bottom forming plates 54 and 56 to maintain the planar nature ofthe product while the edges are being formed.

Cooling water 42 from the final quench tank 46 is allowed to leak backinto the final sizer 40 in order to cool the sheet 10 during sizing. Thecooling water 42 quickly quenches the product below its heat deflectiontemperature to hold its shape. Excess cooling water 42 is removed fromthe sizer 40 by a vacuum pump 34 and is either removed from the systemor recycled back into the quench tank 46.

Following the final sizer operation, the now fully formed extruded sheet10 is immersed in a quench tank 46 to reduce its temperature to aboutthat of ambient air. The continuous sheet is then removed from thequench tank 46. Following the removal of the product from the quenchtank 46, the product can be pulled with the puller machine (not shown)to a cut-off station which severs the now cooled, formed extruded sheetinto individual lengths of shaped polymeric articles.

Some prior art sizers additionally include water cavities therein forcooling the steel forming sections. These cavities are isolated from theextruded profile and serve to draw heat dissipated form the extrudedprofile into the steel shaping sections.

Market and manufacturing pressures are beginning to demand higher outputcapacities from extrusion processes, and thus sizers, in excess of 3000lbs/hr of product. While these prior art extruder designs have provedreliable in the past, they have proved ineffective at meeting theseincreased output demands without sacrificing production quality. Priorart extruders generally require that the product profile cutout withinthe sizer be oversized at least between about 0.012-0.014 inches withrespect to the nominal part thickness of the final cooled product. Thesizer's channel must be oversized because it is unable to pull enoughheat from the product before the product exits the sizer and is cooledin the quenching tank. The steel sizer also heats up, preventingeffective removal of heat from the product. The oversize is necessary toprevent drag between the hot product against the steel sizer. Thesignificant oversize leads to poor dimension control, and ultimately,poor product.

Therefore, there remains a need for a new sizer capable of improvingproduct cooling to allow proper product shaping at higher output rates.

SUMMARY OF THE INVENTION

A sizer assembly for providing a shaped polymeric article in anextrusion process comprises a sizer body having a product profilechannel generally corresponding to the shaped polymeric article to beformed therethrough. The sizer body comprises a plurality of coolingliquid inlet slots forming an opening substantially around the productprofile channel and a plurality of vacuum slots forming an openingsubstantially around the product profile channel for removing coolingliquid expelled from said cooling liquid inlet slots.

A method of manufacturing a shaped polymeric article is also provided. Asheet of extruded hot polymeric material is provided to the sizer forcooling. A length of the sheet is severed after exiting the sizer toproduce the shaped polymeric article.

The sizer provides improved cooling of the polymeric article beingsized. This potentially allows for faster production speeds in excess ofthe limits of current sizers. Faster production speeds improveproduction output. These higher output speeds are accomplished evenusing a tighter, tapered or non-tapered, product channel. More even andconsistent cooling of the product improves product performance throughthe presence of fewer cooled-in stresses. These cooled-in stresses areknown to effect the impact, distortion and shrinkage qualities of theproduct. More accurate dimensioning and reduced product dimensionvariation, more consistent product faces, crisper angles and lessproduct relaxation can also be achieved.

Further, because the cooling liquid pumped into the sizer is the primarymeans of removing heat from the product, the sizer body itself is notrelied upon as the primary heat removal vehicle. It is believed thatthis will allow for the sizer to be manufactured out of lighter, cheaperand/or more wear resistant materials as well as make the sizer easier tomanufacture. Still further, because the sizer need not pull the coolingliquid from a quench tank, more efficient post-sizer cooling mechanismsmay be used, such as a shower or spray tank. Spray bath cooling is moreefficient than submersion cooling and reduces the length of the coolingsection of the extrusion line.

Even further, it is believed the that cooling water pumped into thesizer occupies the tight (e.g., 0.004-0.008 inch) space between theproduct and the sizer channel. The water acts as a lubricant or bearingmechanism that separates the polymeric product and the channel. Thisprevents drag between the product and the sizer and reduces wear on thesizer, thereby permitting the sizer to be manufactured from materialsless wear resistant than steel, if desired.

In still a further embodiment of this invention, a sizer assembly forshaping a polymeric article, which is above its glass transitiontemperature, that is being drawn or extruded is provided. The sizerassembly comprise a sizer body having a product profile channel disposedin a first generally horizontal direction, a plurality of cooling liquidinlet and outlet apertures disposed through the sizer body and in opencommunication with the product profile channel.

The above and other features of the present invention will be betterunderstood from the following detailed description of the preferredembodiments of the invention that is provided in connection with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate preferred embodiments of theinvention, as well as other information pertinent to the disclosure, inwhich:

FIG. 1A is a side elevational view of a prior art sizer coupled to aquenching tank;

FIG. 1B is a cross-sectional view of the prior art sizer of FIG. 1Ataken along lines 1B-1B;

FIG. 2 is a side, cross-sectional view of an exemplary sizer accordingto the present invention;

FIG. 2A is a cross-sectional view of the sizer of FIG. 2 taken alonglines 2A-2A;

FIG. 2B is a cross-sectional view of the sizer of FIG. 2 taken alonglines 2B-2B;

FIG. 3 is a perspective view of an assembled sizer according to thepresent invention; and

FIG. 3A is an exploded view of the sizer of FIG. 3 illustrating thecomponents thereof.

DETAILED DESCRIPTION

FIGS. 2-3A illustrate an exemplary embodiment of a sizer (also know as afixture or calibrator) and sizer assembly for providing a shapedpolymeric article in an extrusion process. The polymeric article can beany shaped polymeric article originating from a flat sheet or non-flatsheet (e.g., having one or more legs or fins formed therein) exiting anextruder having a profile of uniform or non-uniform thickness or havingpre-formed and cooled sections. In an exemplary embodiment, the sizer isshaped to form a siding panel formed from a thermoplastic orthermosetting compositions, such as polyvinyl chloride (“PVC”),polyethylene, polypropylene, polyurethane, epoxy, polyester, orcomposites thereof (e.g., PVC and wood flour composite), etc. or othersimilar materials.

FIG. 2 is a side, cross-sectional view of a sizer 100. An extruded sheetof polymeric material 200 is shown disposed within the sizer 100. Asused herein, “sheet of polymeric material” means a sheet of polymericmaterial of uniform or non-uniform thickness. The sheet may be ofuniform temperature or may be partially preformed and cooled in twodimension or three dimensional form, as taught, for example, in U.S.Pat. No. 6,319,456 to Gilbert discussed in the “Background of theInvention” section. The sizer has body 102 preferably made from steel,although other metals, ceramic materials, wood, plaster, or polymericmaterials such as heat-resistant epoxy, polyoxybenzlene, polymide, PAI(polyamide-imide), silicone, PEI (polyether-imide), PEEK(polyetheretherketone), acrylics, phenolics, and wear surface treatedmaterials (e.g., a diamond coated acrylic), or composites are alsocontemplated, as analyzed in more detail below. The sizer 100 has aproduct profile channel formed through body 102 (shown occupied bypolymeric article 200) corresponding generally to the shape of polymericarticle 200.

The extruded sheet of polymer enters the sizer at a temperature aboveambient. More specifically, portions of the sheet that are to be formedby the sizer are above the polymer's glass transition temperature. Amaterial's glass transition temperature (Tg) is the temperature belowwhich molecules have very little mobility. On a larger scale, polymersare rigid and brittle below their glass transition temperature andelastic above it. Glass transition temperature is usually applicable toamorphous phases and is commonly applicable to glasses and plastics. Byway of example, PVC is generally formable above 170° F.

In an exemplary embodiment, the portions of the product profile channelused to size and shape the polymeric product are sized less than 0.012″,preferably between about 0.001-0.012″, and more preferably between about0.004-0.008″, greater than the nominal part thickness of the finalprofile size of the shaped polymeric article. This is a reduction fromthe standard 0.012-0.014″ oversize described in the “Background”section. As described in more detail below, it is believed that thisreduction is made possible by the improved heat removal abilities of thesizer 100. Further, the reduced size allows for the cooling liquid toact as a bearing mechanism between the product and the sizer profilechannel.

In an exemplary embodiment, the sizer 100 includes a plurality ofcooling liquid inlet apertures, such as slots 106, holes or combinationsthereof, forming an opening partially, or substantially around, andpreferably entirely around, the product profile channel. These aperturesmay be isolated to specific areas of the panel profile, if desired, toallow individual control of cooling liquid flows in contact withspecific regions of the polymeric article. Each slot 106 is preferablycoupled to a plurality of upper and lower cooling liquid inlet ports 104that provide access to slots 106 for a cooling liquid, such as water. Asbest shown in the cross-sectional view of FIG. 2B taken along lines2B-2B of FIG. 2, an exemplary sizer 100 includes six inlet ports 104disposed around each slot 106. As best shown in FIG. 2, a sizer 100having a length L of approximately 4.0″ has three spaced slots 106formed therein.

Cooling liquid inlet slots and ports should be sized to allow foradequate cooling liquid volumes and the desired liquid distribution overthe product, which depend on such factors as the shape of the product,the speed of the product and the temperature of the product. In anexemplary embodiment, cooling liquid inlet slots 106 have a width W₁between about 0.020″-0.500″ and preferably at least about 0.25″. Inletports 104 have diameters between about 0.250″-1.00″, and preferably atleast about 0.5″.

Sizer 100 preferably includes a plurality of spaced outlet apertures,such as vacuum slots 108, forming an opening partially, or substantiallyaround, and preferably entirely around, the product profile channel fordraining and/or removing cooling liquid expelled from the cooling liquidinlet slots 106. The vacuum slots 108 are preferably disposed before, inbetween and/or after the cooling liquid inlet slots 106, as best seen inFIG. 2. The cross-section view of FIG. 2A taken along lines 2A-2A ofFIG. 2 illustrates a slot 108 forming an opening entirely around theproduct profile channel. The direction of the product profile throughthe sizer 100 is illustrated by directional arrows in FIG. 2. The firstvacuum slot 108 disposed closest to the entrance of the sizer 100 helpsto ensure that cooling liquid does not escape through the entrance ofthe sizer.

Vacuum slots 108 are preferably sized to achieve relative evendistribution of vacuum forces. In an exemplary embodiment of sizer 100,vacuum slots 108 have a width W₂ between about 0.010″-0.250″, andpreferably at least 0.04″.

FIG. 3 is a perspective view of an exemplary sizer assembly 300, andFIG. 3A is an exploded view showing the components thereof. The sizerbody is formed from one or more sections defining the product profilechannel. In the illustrated embodiment, sizer assembly 300 includes asizer 100 including four steel sections 306, 308, 310, 312 that matetogether to define the product profile channel through the sizer 100.The inlet ports 104 can be seen in top section 306 of sizer 100. Similarinlet ports (not shown) may be found on the underside of bottom section308. The vacuum slots 108 and water slots 106 are visible in theexploded view of FIG. 3A.

The sizer assembly 300 includes top and bottom aluminum manifolds 302and 304, respectively. Although shown as separate parts of a sizerassembly 300, it is contemplated that the manifold can be formedintegrally with the sizer 100. The top manifold 302 is shown secured tothe top sizer section 306 via bolts disposed within holes 318, but themanifold sections may be coupled to the sizer by other means, such as bypiping sections. Bolting plates 316 are bolted to bottom manifold 304.Rectangular side panels 314 are bolted to intermediate sizer sections310, 312. Holes 324 are shown drilled for insertion of toggle handles(not shown in FIGS. 3, 3A) as described in connection with prior artFIGS. 1A, 1B for securing sections 310, 312 in sizer 100.

It should be understood that manifold sections 302, 304 may be designedin any number of configurations. The only requirement for manifolds 302,304 is that the vacuum/suction chambers and cooling liquid chambers beisolated within the manifold so that there is no interchangetherebetween. In an exemplary embodiment, manifold sections 302, 304have essentially the same connection system formed therein.

An exemplary manifold section 302, 304 includes cooling liquid (e.g.,water) inlet ports 320 drilled therein from the top side, eachcorresponding to a group of three inlet ports 104 formed into a top orbottom section 306, 308. Ports 320 preferably have a diameter of atleast about ½″. Water slots 328 are machined into the manifolds 302, 304to a depth of about ¾″. The water slots 328 are connected to the inletports 320 by side channels 326 drilled into the manifolds 302, 304.Although side channels 326 are shown open, the ends of these channelsare plugged when the sizer is in use in order to prevent liquid fromescaping and air from entering. Each inlet port 320 on the manifolds302, 304 can be connected to a separate water pump and be individuallycontrolled if desired. Individual control may be desirable if more orless cooling is required or desired at specific locations of thepolymeric article. This control may also be achieved by isolating inletslots or inlet ports to specific regions of the polymeric article asnoted above.

An exemplary manifold section 302, 304 also includes three draining,vacuum and/or suction ports 322 drilled therein. Suction ports 322preferably have a diameter of at least about ½″. Vacuum slots 330 aremachined about ¼″ into the manifolds 302, 304 and correspond to vacuumslots 108 formed in the sizer 100. Side channels 323 are drilled acrossthe manifolds 302, 304 and intersect vacuum ports 322. Although thechannels 323 are shown open, the ends of these channels 323 are pluggedwhen the sizer is in use in order to prevent liquid from escaping duringremoval of the liquid. Twelve connection holes 325 are drilled throughthe manifolds 302, 304 in vacuum slots 330 to intersect side channels323, thereby coupling ports 322 to slots 330. In an exemplaryembodiment, each port 322 on top manifold 302 and each port 322 onbottom manifold 304 are coupled to a single suction source (e.g., apump) for removal of cooling liquid, e.g., water. However, it iscontemplated that the vacuum slots or apertures may be configured forindividual control.

In operation, the sizer 100 primarily utilizes a large volume of coolingliquid, preferably water, to cool the polymeric product profile as itmoves through the sizer. The product profile 200 typically has atemperature of between about 240-260° F. as it enters the sizer 100.Water is pumped into the sizer assembly through ports 320, where itenters channels 326 and then enters water slots 328 of manifolds 302,304. It is preferred to utilizes a water slot configuration (i.e., waterslots 328) in order to balance water flows and pressure around theproduct and to prevent flow from “short cutting” through the system. Thewater slots 328 overlap inlet ports 104 of sizer 100, which connect tocooling liquid inlet slots 106 so that water contacts the product 200,removing heat therefrom. The water cools the product and provides abearing layer between the product 200 and the product profile channeldefined through the sizer 100. The water is then removed via vacuumslots 108 as described below.

The amount of cooling liquid injected into cooling liquid inlet slots106 is preferably individually controlled for each port 320, butpreferably ranges between about 1.5-6.0 GPM (gallons per minute) perport 320. In the embodiment shown in FIGS. 2-3A, this range amounts tobetween about 0.5-2 GPM per inlet port 104. The suction placed on vacuumslots 108 is preferably evenly distributed across the vacuum slots andfrom the entry to exit points of the sizer.

As mentioned, water is removed from the sizer 100 via vacuum slots 108of sizer 100. The vacuum slots 108 overlap slots 330 machined into themanifolds 302, 304 of the sizer assembly 300. The water enters holes 325from slots 330 and is pulled into channels 323 through to vacuum ports322, where it is removed from the assembly 300. In operation, eachvacuum port 322 preferably operate at a force or vacuum level sufficientto suction water from the vacuum slot opening at a rate equal to orabove the rate the cooling liquid is fed through the inlet ports. In oneembodiment, each vacuum port 322 operates at a force greater than 10″vacuum.

As mentioned, the sizer 100 and sizer assembly 300 may be used in theformation of a shaped polymeric article in an extrusion process. Thedetails of the extrusion process and the components therein should befamiliar to those of ordinary skill and are summarized hereafter. A flatsheet of a polymeric material, such as PVC, is extruded. A wood grainfinish or other finish may optionally be applied to the extruded sheetin a press roller or areas may be pre-formed and cooled via other means,such as those described in U.S. Pat. No. 6,319,456 to Gilbert. A coolingroller or other method is used to reduce the PVC temperature from about400° F. to about 250° F. The PVC sheet is then optionally applied to oneor more pre-sizers to shape the product. After the pre-sizer, the PVCsheet is provided to the sizer 100 of sizer assembly 300. After thesizer, the shaped polymeric article is typically pulled through aquenching tank. After exiting the quenching tank, the shaped polymericarticle is cut into appropriate lengths for a final product.

The improved heat removal capabilities of the new sizer design asdescribed above were verified using finite element analysis (FEA) usingapproximately a 200,000 element model for a prior art sizer and the newsizer design. The velocity of the PVC sheet, the conductivity of waterand air, the cooling water temperature and convection coefficient, andthe thermal conductivity and heat capacity of the polymer were allvariables in the analysis. Observation of thermal isobars for the priorart sizer design and new sizer design, as well as the product movingthrough the designs, revealed more uniform increased BTU removal in theproduct sized with the new design and less heat dissipation from theproduct into the new sizer body. This indicates that the cooling waterserved as the primary heat removal vehicle.

The sizer 100 described above was also built and tested. Test resultsindicated that the tested sizer design was capable of pulling over 800BTUs per minute from the product, based on tests on the cooling waterduring a product run where the input product surface temperature wasmeasured at 245° F., the output product surface temperature was measuredat 140° F. and the product speed was about 1800 inches per minute.

The sizer 100 provides several advantages. The sizer provides improvedcooling of the polymeric article being sized. This allows for fasterproduction speeds in excess of the estimated 3900 lb/hr limit of currentsizers. Faster production speeds improve production output. These higheroutput speeds are accomplished even using a tighter, non-tapered productchannel, which provides more accurate dimensioning and reduced productdimension variation. Indeed, more consistent product faces, crisperangles and less product relaxation were observed using the sizer.

It should be understood that the channel of the sizer described hereinhas a substantially uniform shape, but may be implemented with all,portions or none of the channel being tapered. Still further, portionsof the channel may be oversized with respect to the product while otherportions are characterized by less or little oversize. Thisconfiguration may be utilized, for example, when various portions of theproduct are pre-formed and cooled prior to the sizer.

Further, because the cooling liquid pumped into the sizer is the primarymeans of removing heat from the product, the sizer body itself is notrelied upon as the primary heat removal vehicle. Put another way, thethermal conductivity of the steel is not required to remove heat fromthe product. It is believed that this will allow for the sizer to bemanufactured out of lighter, cheaper and/or more wear resistantmaterials, such as polymeric materials such as heat-resistant epoxy,polyoxybenzlene, polymide, PAI (polyamide-imide), silicone, PEI(polyether-imide), PEEK (polyetheretherketone), acrylics, phenolics,composites, and wear surface treated materials (e.g., a diamond coatedacrylic). Other metals, ceramic materials, wood, plaster, or compositesare also contemplated. Cooler water can also be used to cool the productbecause a source of water other than the quenching tank can be used.Higher volumes of water are used to cool the product, leading toimproved cooling. Still further, because the sizer 100 need not pull thecooling liquid from a quench tank, more efficient post-sizer coolingmechanisms may be used, such as a shower or spray tank. Spray bathcooling is more efficient than submersion cooling and reduces the lengthof the cooling section of the extrusion line.

Even further, it is believed the that cooling water pumped into thesizer occupies the tight (e.g., 0.004-0.008 inch) space between theproduct and the sizer channel. The water acts as a lubricant or bearingmechanism that separates the polymeric product and the channel. Thisprevents drag between the product and the sizer and reduces wear on thesizer, thereby permitting the sizer to be formed from materials that areless wear resistant than steel, if desired.

Although the invention has been described in terms of exemplaryembodiments, it is not limited thereto. Rather, the appended claimsshould be construed broadly to include other variants and embodiments ofthe invention that may be made by those skilled in the art withoutdeparting from the scope and range of equivalents of the invention.

1. A method of manufacturing a non-hollow, shaped polymeric article,comprising the steps of: providing a generally flat extruded sheet ofhot polymeric material having an outer surface to a sizer assembly forcooling and shaping said polymeric sheet into a non-hollow, shapedpolymeric article, wherein said sizer assembly comprises: a sizer bodyhaving a product profile channel corresponding to said shaped polymericarticle formed therethrough, said sizer body further comprising aplurality of cooling liquid inlet slots each forming an openingsubstantially around said product profile channel, said cooling liquidinlet slots being in open communication with said product profilechannel, and a plurality of vacuum slots each forming an openingsubstantially around said product profile channel for removing coolingliquid expelled from said cooling liquid inlet slots, said vacuum slotsbeing interspersed among, and fluidly insulated from said cooling liquidinlet slots, except in said product profile channel, and being coupledto at least one vacuum source; controlling at least one of vacuum andcooling liquid levels at said product profile channel such that asubstantial portion of said outer surface of said sheet of polymericmaterial is maintained away from said sizer body as said sheet ofpolymeric material passes through said sizer; and severing a length ofsaid sheet after exiting said sizer to produce said shaped polymericarticle.
 2. The method of claim 1, further comprising the step ofcooling said sheet after said providing step in a quenching tank.
 3. Themethod of claim 1, further comprising the step of cooling said sheetafter said providing step in a spray bath.
 4. The method of claim 1,wherein the product profile channel has a substantially uniform shapealong its longitudinal axis and is sized less than 0.012 inches greaterthan a nominal thickness of said shaped polymeric article.
 5. The methodof claim 1, wherein the product profile channel has a substantiallyuniform shape along its longitudinal axis and is sized between about0.004-0.008 inches greater than a nominal thickness of said shapedpolymeric article.
 6. The method of claim 5, wherein said methodprovides at least 3900 lb/hr of polymeric product.
 7. The method ofclaim 1, wherein said sizer body is formed from a polymeric materialselected from the group consisting of heat-resistant epoxy,polyoxybenzlene, polymide, polyamide-imide, silicone, polyether-imide,polyetheretherketone, acrylics and phenolics.
 8. The method of claim 1,wherein, for a sizer approximately 4.0 inches in length, said sizerpulls at least about 800 BTUs/minute from said extruded sheet at aproduct speed of about 1800 inches per minute, or proportionate amountsof BTUs/minute for different sized sizers.
 9. The method of claim 1,wherein said controlling step comprises providing to and removing fromsaid product profile channel at least 9 gallons per minute of saidcooling liquid.
 10. The method of claim 1, wherein said controlling stepcomprises providing to and removing from said product profile channelbetween about 9-36 gallons per minute of said cooling liquid.
 11. Themethod of claim 1, wherein said cooling liquid inlet slots are generallyorthogonal to the longitudinal axis of said product profile channel andsaid vacuum slots are interspersed among said cooling liquid inletslots.
 12. The method of claim 1, wherein said sizer body has an top andbottom surfaces and a pair of side surfaces, wherein at least some ofsaid vacuum slots are formed completely through said sizer body fromsaid top surface to said bottom surface intermediate said side surfaces,and wherein at least some of said cooling liquid inlet slots are formedonly partially through said sizer body between said top and bottomsurfaces, said sizer body further comprising a plurality of coolingliquid inlet ports formed in said sizer body for providing access tosaid cooling liquid inlet slots formed only partially through said sizerbody.
 13. The method of claim 12, further comprising top and bottommanifold sections coupled to said sizer body, each of said top andbottom manifold sections including at least one input port coupled tosaid at least one source of cooling liquid and at least one vacuum portcoupled to said at least one vacuum source, said manifold sectionsfurther being configured to place said at least one source of coolingliquid in communication with said cooling liquid inlet ports of saidsizer body and to place said at least one vacuum source in communicationwith said at least some of said vacuum slots.
 14. A method ofmanufacturing a non-hollow, shaped polymeric article, comprising thesteps of: providing a generally flat sheet of hot polymeric materialhaving an outer surface to a sizer assembly for cooling and shaping saidpolymeric sheet into a non-hollow, shaped polymeric article, saidpolymeric sheet being above its glass transition temperature, whereinsaid sizer assembly comprises: a sizer body having a product profilechannel disposed in a first generally horizontal direction, a pluralityof longitudinally spaced cooling liquid inlet and outlet aperturesdisposed through said sizer body and in open communication with saidproduct profile channel, said cooling liquid outlet apertures beinginterspersed among, and fluidly insulated from said cooling liquid inletapertures, except in said product profile channel, said cooling liquidoutlet apertures being coupled to at least one vacuum source;controlling at least one of vacuum and cooling liquid levels at saidproduct profile channel such that a substantial portion of said outersurface of said sheet of polymeric material is maintained away from saidsizer body, thereby reducing drag on said sheet of polymeric material asit passes through said sizer; and severing a length of said sheet afterexiting said sizer to produce said shaped polymeric article.
 15. Themethod of claim 14, wherein said outlet apertures are alternatinglyarranged with said inlet apertures.
 16. The method of claim 14, whereina portion of said plurality of cooling liquid inlet and outlet aperturesare disposed orthogonal to said generally horizontal product profilechannel.
 17. A method of manufacturing a non-hollow, shaped polymericarticle, comprising the steps of: providing a generally flat extrudedsheet of hot polymeric material having an outer surface to a sizerassembly for cooling and shaping said polymeric sheet into a non-hollow,shaped polymeric article, said sizer assembly comprising a sizer bodyhaving a product profile channel corresponding to said shaped polymericarticle formed therethrough; providing at least one source of coolingliquid for said sizer assembly; providing at least one vacuum source forsaid sizer assembly; and controlling the vacuum and cooling liquidlevels at said product profile channel such that a substantial portionof said outer surface of said sheet of polymeric material is maintainedaway from said sizer body as said sheet of polymeric material passesthrough said sizer.
 18. The method of claim 17, wherein the productprofile channel has a substantially uniform shape along its longitudinalaxis and is sized less than 0.012 inches greater than a nominalthickness of said shaped polymeric article.
 19. The method of claim 17,wherein the product profile channel has a substantially uniform shapealong its longitudinal axis and is sized between about 0.004-0.008inches greater than a nominal thickness of said shaped polymericarticle.
 20. The method of claim 19, wherein said controlling stepcomprises providing to and removing from said product profile channel atleast 9 gallons per minute of said cooling liquid